Abstract:

Disclosed are compositions comprising: (i) 5-45 wt. % of an
acrylonitrile-styrene-acrylate (ASA) graft copolymer or acrylate-modified
ASA, (ii) 2-82 wt. % of at least one polyestercarbonate which is a block
polyestercarbonate comprising organic carbonate blocks alternating with
arylate blocks, said arylate blocks comprising ester structural units
derived from at least one 1,3-dihydroxybenzene moiety and at least one
aromatic dicarboxylic acid, and having a degree of polymerization of at
least about 4; and (iii) 5-60 wt. % of at least one rigid thermoplastic
polymer comprising structural units derived from styrene and
acrylonitrile; alpha-methylstyrene and acrylonitrile;
alpha-methylstyrene, styrene, and acrylonitrile; styrene, acrylonitrile,
and methyl methacrylate; alpha-methyl styrene, acrylonitrile, and methyl
methacrylate; or alpha-methylstyrene, styrene, acrylonitrile, and methyl
methacrylate, or mixtures thereof, wherein wt. % values are based on the
weight of components (i)-(iii) and wherein a molded article made from the
composition has a notched Izod impact strength of at least 5 kilojoules
per square meter (kJ/m2) as determined according to ISO 180 at room
temperature and a Vicat B value of at least 101° C. determined at
120° C. according to ISO 306. Articles made from said compositions
are also disclosed.

Claims:

1. A composition comprising (i) 5-45 wt. % of an
acrylonitrile-styrene-acrylate (ASA) graft copolymer or acrylate-modified
ASA, (ii) 2-82 wt. % of at least one polyestercarbonate which is a block
polyestercarbonate comprising organic carbonate blocks alternating with
arylate blocks, said arylate blocks comprising ester structural units
derived from at least one 1,3-dihydroxybenzene moiety and at least one
aromatic dicarboxylic acid, and having a degree of polymerization of at
least about 4; and (iii) 5-60 wt. % of at least one rigid thermoplastic
polymer comprising structural units derived from styrene and
acrylonitrile; alpha-methylstyrene and acrylonitrile;
alpha-methylstyrene, styrene, and acrylonitrile; styrene, acrylonitrile,
and methyl methacrylate; alpha-methyl styrene, acrylonitrile, and methyl
methacrylate; or alpha-methylstyrene, styrene, acrylonitrile, and methyl
methacrylate, or mixtures thereof, wherein wt. % values are based on the
weight of components (i)-(iii) and wherein a molded article made from the
composition has a notched Izod impact strength of at least 5 kilojoules
per square meter (kJ/m2) as determined according to ISO 180 at room
temperature and a Vicat B value of at least 101.degree. C. determined at
120.degree. C. according to ISO 306.

2. The composition of claim 1, wherein the carbonate blocks of the
polyestercarbonate comprise structural units derived from those selected
from the group consisting of bisphenol A, unsubstituted resorcinol, and
mixtures thereof.

3. The composition of claim 1, wherein the carbonate blocks of the
polyestercarbonate have a degree of polymerization of at least about 3.

4. The composition of claim 1, wherein the ester structural units of the
polyestercarbonate are derived from at least one of unsubstituted
resorcinol or a substituted resorcinol, in combination with isophthalate
or terephthalate or a mixture thereof.

5. The composition of claim 4, wherein the ester structural units are
derived from moieties comprising a mixture of isophthatate and
terephthalate.

6. The composition of claim 5, wherein the molar ratio of isophthalate to
terephthalate in the ester structural units is in the range of about
0.25-4.0:1.

7. The composition of claim 1, wherein the arylate blocks of the
polyestercarbonate have a degree of polymerization of at least about 10.

8. The composition of claim 1, wherein the polyestercarbonate comprises
about 10-99% by weight arylate blocks.

9. The composition of claim 1, wherein the ASA (i) is present in an amount
in a range of between about 30 wt. % and about 45 wt. %; the
polyestercarbonate (ii) is present in an amount in a range of between
about 4 wt. % and about 25 wt. %; and the rigid thermoplastic polymer
(iii) is present in an amount in a range of between about 35 wt. % and
about 55 wt. %.

10. The composition of claim 1, wherein the ASA (i) is present in an
amount in a range of between about 15 wt. % and about 35 wt. %; the
polyestercarbonate (ii) is present in an amount in a range of between
about 30 wt. % and about 75 wt. %; and the rigid thermoplastic polymer
(iii) is present in an amount in a range of between about 15 wt. % and
about 35 wt. %.

11. The composition of claim 10, wherein a molded article made from the
composition has a notched Izod impact strength of at least 20 kJ/m2
as determined according to ISO 180 at room temperature.

12. The composition of claim 1, further comprising at least one additive
selected from the group consisting of a colorant, dye, pigment,
lubricant, stabilizer, heat stabilizer, light stabilizer, antioxidant UV
screener, UV absorber, and mixtures thereof.

13. The composition of claim 1, which shows less than 10% decrease in
notched Izod impact strength (NII) value as determined according to ISO
180 at room temperature over a range of 5-20 wt. % polyestercarbonate
content, based on the weight of the entire composition.

14. An article made from the composition of claim 1.

15. A composition comprising (i) 19-33 wt. % of an
acrylonitrile-styrene-acrylate (ASA) graft copolymer or acrylate-modified
ASA, (ii) 34-61 wt. % of at least one polyestercarbonate which is a block
polyestercarbonate comprising organic carbonate blocks alternating with
arylate blocks, said arylate blocks comprising ester structural units
derived from at least one 1,3-dihydroxybenzene moiety and at least one
aromatic dicarboxylic acid, and having a degree of polymerization of at
least about 4; and (iii) 19-33 wt. % of at least one rigid thermoplastic
polymer comprising structural units derived from styrene and
acrylonitrile; alpha-methylstyrene and acrylonitrile;
alpha-methylstyrene, styrene, and acrylonitrite; styrene, acrylonitrile,
and methyl methacrylate; alpha-methyl styrene, acrylonitrile, and methyl
methacrylate; or alpha-methylstyrene, styrene, acrylonitrile, and methyl
methacrylate, or mixtures thereof, wherein wt. % values are based on the
weight of components (i)-(iii) and wherein a molded article made from the
composition has a notched Izod impact strength of at least 30 kilojoules
per square meter (kJ/m2) as determined according to ISO 180 at room
temperature, a Vicat B value of at least 101.degree. C. determined at
120.degree. C. according to ISO 306, and a value for dE of less than or
equal to about 4 after weathering of test parts performed according to
the SAEJ1960 protocol through 2500 kJ/m2 exposure (measured at 340
nm).

16. The composition of claim 15, wherein the polyestercarbonate is present
in an amount in a range of 39-56 wt. %

17. The composition of claim 15, wherein the polyestercarbonate is present
in an amount in a range of 48-52 wt. %

18. The composition of claim 15, further comprising at least one additive
selected from the group consisting of a colorant, dye, pigment,
lubricant, stabilizer, heat stabilizer, light stabilizer, antioxidant, UV
screener, UV absorber, and mixtures thereof.

[0002]ASA resin typically has excellent weatherability and processability
properties. When it is desired to make ASA formulations with higher heat
properties, blends are usually prepared comprising ASA and
α-methylstyrene-acrylonitrile copolymer (AMSAN) or ASA and
maleimide-containing polymers. However, the maximum obtainable heat
properties in such blends are rather low due to the low maximum glass
transition temperature (Tg) of the materials, typically about 120°
C. Furthermore, maleimide-containing polymers may have toxic properties
and therefore are not suitable for many commercially applications. Better
heat properties can be obtained in ASA blends with polycarbonate (PC),
which latter polymer has a Tg of about 145° C. However, it is
known that the addition of polycarbonate to ASA formulations can reduce
the impact strength in molded articles comprising such compositions. In
addition, the discoloration of these ASA-PC formulations upon weathering
is usually severe due to the limited weatherability of polycarbonate.
Hence, there is a continued need for ASA blends that possess an
attractive balance of thermal and physical properties while retaining
weatherability in molded articles.

[0003]ASA is taught as an impact modifier in compositions containing
polyestercarbonate in U.S. Pat. No. 6,583,256. However, exemplary
compositions also require the presence of a poly(alkylene dicarboxylate)
which renders the compositions unsuitable for some applications. In
particular the use of poly(alkylene dicarboxylate)s such as poly(butylene
terephthalate) typically results in a composition with low impact
strength and less than optimal weathering properties.

BRIEF DESCRIPTION

[0004]The present invention relates to a composition comprising an ASA
resin and a polyestercarbonate, which surprisingly shows no decrease in
impact strength over a range of polyestercarbonate levels in contrast to
compositions wherein a comparable amount of polycarbonate replaces the
polyestercarbonate. The composition of matter posses an attractive
balance of other physical, weathering and thermal properties. Thus, in
one embodiment the present invention comprises a composition comprising
(i) 5-45 wt. % of an acrylonitrile-styrene-acrylate (ASA) graft copolymer
or acrylate-modified ASA, (ii) 2-82 wt. % of at least one
polyestercarbonate which is a block polyestercarbonate comprising organic
carbonate blocks alternating with arylate blocks, said arylate blocks
comprising ester structural units derived from at least one
1,3-dihydroxybenzene moiety and at least one aromatic dicarboxylic acid,
and having a degree of polymerization of at least about 4; and (iii) 5-60
wt. % of at least one rigid thermoplastic polymer comprising structural
units derived from styrene and acrylonitrile; alpha-methylstyrene and
acrylonitrile; alpha-methylstyrene, styrene, and acrylonitrile; styrene,
acrylonitrile, and methyl methacrylate; alpha-methyl styrene,
acrylonitrile, and methyl methacrylate; or alpha-methylstyrene, styrene,
acrylonitrile, and methyl methacrylate, or mixtures thereof, wherein wt.
% values are based on the weight of components (i)-(iii) and wherein a
molded article made from the composition has a notched Izod impact
strength of at least 5 kilojoules per square meter (kJ/m2) as
determined according to ISO 180 at room temperature and a Vicat B value
of at least 101° C. determined at 120° C. according to ISO
306.

[0005]In still other embodiments the present invention comprises articles
made from said compositions. Various other features, aspects, and
advantages of the present invention will become more apparent with
reference to the following description and appended claims.

DETAILED DESCRIPTION

[0006]In the following specification and the claims which follow,
reference will be made to a number of terms which shall be defined to
have the following meanings. The singular forms "a", "an" and "the"
include plural referents unless the context clearly dictates otherwise.
The terminology "monoethylenically unsaturated" means having a single
site of ethylenic unsaturation per molecule. The terminology
"polyethylenically unsaturated" means having two or more sites of
ethylenic unsaturation per molecule. The terminology "(meth)acrylate"
refers collectively to acrylate and methacrylate; for example, the term
"(meth)acrylate monomers" refers collectively to acrylate monomers and
methacrylate monomers. The term "(meth)acrylamide" refers collectively to
acrylamides and methacrylamides.

[0007]The term "alkyl" as used in the various embodiments of the present
invention is intended to designate linear alkyl, branched alkyl, aralkyl,
cycloalkyl, bicycloalkyl, tricycloalkyl and polycycloalkyl radicals
containing carbon and hydrogen atoms, and optionally containing atoms in
addition to carbon and hydrogen, for example atoms selected from Groups
15, 16 and 17 of the Periodic Table. Alkyl groups may be saturated or
unsaturated, and may comprise, for example, vinyl or allyl. The term
"alkyl" also encompasses that alkyl portion of alkoxide groups. In
various embodiments normal and branched alkyl radicals are those
containing from 1 to about 32 carbon atoms, and include as illustrative
non-limiting examples C1-C32 alkyl (optionally substituted with
one or more groups selected from C1-C32 alkyl, C3-C15
cycloalkyl or aryl); and C3-C15 cycloalkyl optionally
substituted with one or more groups selected from C1-C32 alkyl.
Some particular illustrative examples comprise methyl, ethyl, n-propyl,
isopropyl, n-butyl, sec-butyl, tertiary-butyl, pentyl, neopentyl, hexyl,
heptyl, octyl, nonyl, decyl, undecyl and dodecyl. Some illustrative
non-limiting examples of cycloalkyl and bicycloalkyl radicals include
cyclobutyl, cyclopentyl, cyclohexyl, methylcyclohexyl, cycloheptyl,
bicycloheptyl and adamantyl. In various embodiments aralkyl radicals are
those containing from 7 to about 14 carbon atoms; these include, but are
not limited to, benzyl, phenylbutyl, phenylpropyl, and phenylethyl. The
term "aryl" as used in the various embodiments of the present invention
is intended to designate substituted or unsubstituted aryl radicals
containing from 6 to 20 ring carbon atoms. Some illustrative non-limiting
examples of these aryl radicals include C6-C20 aryl optionally
substituted with one or more groups selected from C1-C32 alkyl,
C3-C15 cycloalkyl, aryl, and functional groups comprising atoms
selected from Groups 15, 16 and 17 of the Periodic Table. Some particular
illustrative examples of aryl radicals comprise substituted or
unsubstituted phenyl, biphenyl, tolyl, naphthyl and binaphthyl.

[0008]Compositions in embodiments of the present invention comprise a
rubber modified thermoplastic resin comprising a discontinuous
elastomeric phase dispersed in a rigid thermoplastic phase, wherein at
least a portion of the rigid thermoplastic phase is grafted to the
elastomeric phase. The rubber modified thermoplastic resin employs at
least one rubber substrate for grafting. The rubber substrate comprises
the discontinuous elastomeric phase of the composition. There is no
particular limitation on the rubber substrate provided it is susceptible
to grafting by at least a portion of a graftable monomer. In some
embodiments suitable rubber substrates comprise dimethyl siloxane/butyl
acrylate rubber, or silicone/butyl acrylate composite rubber; polyolefin
rubbers such as ethylene-propylene rubber or ethylene-propylene-diene
(EPDM) rubber; or silicone rubber polymers such as polymethylsiloxane
rubber. The rubber substrate typically has a glass transition
temperature, Tg, in one embodiment less than or equal to 25° C.,
in another embodiment below about 0° C., in another embodiment
below about minus 20° C., and in still another embodiment below
about minus 30° C. As referred to herein, the Tg of a polymer is
the T value of polymer as measured by differential scanning calorimetry
(DSC; heating rate 20° C./minute, with the Tg value being
determined at the inflection point).

[0009]In one embodiment the rubber substrate is derived from
polymerization by known methods of at least one monoethylenically
unsaturated alkyl (meth)acrylate monomer selected from
(C1-C12)alkyl(meth)acrylate monomers and mixtures comprising at
least one of said monomers. As used herein, the terminology
"(C1-Cy)", as applied to a particular unit, such as, for
example, a chemical compound or a chemical substituent group, means
having a carbon atom content of from "x" carbon atoms to "y" carbon atoms
per such unit. For example, "(C1-C12)alkyl" means a straight
chain, branched or cyclic alkyl substituent group having from 1 to 12
carbon atoms per group. Suitable (C1-C12)alkyl(meth)acrylate
monomers include, but are not limited to, (C1-C12)alkyl
acrylate monomers, illustrative examples of which comprise ethyl
acrylate, butyl acrylate, iso-pentyl acrylate, n-hexyl acrylate, and
2-ethyl hexyl acrylate; and their (C1-C12)alkyl methacrylate
analogs, illustrative examples of which comprise methyl methacrylate,
ethyl methacrylate, propyl methacrylate, iso-propyl methacrylate, butyl
methacrylate, hexyl methacrylate, and decyl methacrylate.

[0010]In various embodiments the rubber substrate may also optionally
comprise a minor amount, for example up to about 5 wt. %, of structural
units derived from at least one polyethylenically unsaturated monomer,
for example those that are copolymerizable with a monomer used to prepare
the rubber substrate. A polyethylenically unsaturated monomer is often
employed to provide cross-linking of the rubber particles and/or to
provide "graftlinking" sites in the rubber substrate for subsequent
reaction with grafting monomers. Suitable polyethylenically unsaturated
monomers include, but are not limited to, butylene diacrylate, divinyl
benzene, butene diol dimethacrylate, trimethylolpropane
tri(meth)acrylate, allyl methacrylate, diallyl methacrylate, diallyl
maleate, diallyl fumarate, diallyl phthalate, triallyl methacrylate,
triallyl cyanurate, triallyl isocyanurate, the acrylate of
tricyclodecenylalcohol and mixtures comprising at least one of such
monomers. In a particular embodiment the rubber substrate comprises
structural units derived from triallyl cyanurate.

[0011]In some embodiments the rubber substrate may optionally comprise
structural units derived from minor amounts of other unsaturated
monomers, for example those that are copolymerizable with a monomer used
to prepare the rubber substrate. In particular embodiments the rubber
substrate may optionally include up to about 25 wt. % of structural units
derived from one or more monomers selected from (meth)acrylate monomers,
alkenyl aromatic monomers and monoethylenically unsaturated nitrile
monomers. Suitable copolymerizable (meth)acrylate monomers include, but
are not limited to, C1-C12 aryl or haloaryl substituted
acrylate, C1-C12 aryl or haloaryl substituted methacrylate, or
mixtures thereof; monoethylenically unsaturated carboxylic acids, such
as, for example, acrylic acid, methacrylic acid and itaconic acid;
glycidyl (meth)acrylate, hydroxy alkyl (meth)acrylate,
hydroxy(C1-C12)alkyl (meth)acrylate, such as, for example,
hydroxyethyl methacrylate; (C4-C12)cycloalkyl (meth)acrylate
monomers, such as, for example, cyclohexyl methacrylate; (meth)acrylamide
monomers, such as, for example, acrylamide, methacrylamide and
N-substituted-acrylamide or N-substituted-methacrylamides; maleimide
monomers, such as, for example, maleimide, N-alkyl maleimides, N-aryl
maleimides, N-phenyl maleimide, and haloaryl substituted maleimides;
maleic anhydride; methyl vinyl ether, ethyl vinyl ether, and vinyl
esters, such as, for example, vinyl acetate and vinyl propionate.
Suitable alkenyl aromatic monomers include, but are not limited to, vinyl
aromatic monomers, such as, for example, styrene and substituted styrenes
having one or more alkyl, alkoxy, hydroxy or halo substituent groups
attached to the aromatic ring, including, but not limited to,
alpha-methyl styrene, p-methyl styrene, 3,5-diethylstyrene,
4-n-propylstyrene, 4-isopropylstyrene, vinyl toluene, alpha-methyl vinyl
toluene, vinyl xylene, trimethyl styrene, butyl styrene, t-butyl styrene,
chlorostyrene, alpha-chlorostyrene, dichlorostyrene, tetrachlorostyrene,
bromostyrene, alpha-bromostyrene, dibromostyrene, p-hydroxystyrene,
p-acetoxystyrene, methoxystyrene and vinyl-substituted condensed aromatic
ring structures, such as, for example, vinyl naphthalene, vinyl
anthracene, as well as mixtures of vinyl aromatic monomers and
monoethylenically unsaturated nitrile monomers such as, for example,
acrylonitrile, ethacrylonitrile, methacrylonitrile,
alpha-bromoacrylonitrile and alpha-chloro acrylonitrile. Substituted
styrenes with mixtures of substituents on the aromatic ring are also
suitable. As used herein, the term "monoethylenically unsaturated nitrile
monomer" means an acyclic compound that includes a single nitrile group
and a single site of ethylenic unsaturation per molecule and includes,
but is not limited to, acrylonitrile, methacrylonitrile, alpha-chloro
acrylonitrile, and the like.

[0012]In a particular embodiment the rubber substrate comprises repeating
units derived from one or more (C1-C12)alkyl acrylate monomers.
In still another particular embodiment, the rubber substrate comprises
from 40 to 95 wt. % repeating units derived from one or more
(C1-C12)alkyl acrylate monomers, and more particularly from one
or more monomers selected from ethyl acrylate, butyl acrylate and n-hexyl
acrylate. In a particular embodiment of the present invention the rubber
substrate comprises structural units derived from n-butyl acrylate.

[0013]The rubber substrate may be present in the rubber modified
thermoplastic resin in one embodiment at a level of from about 4 wt. % to
about 94 wt. %; in another embodiment at a level of from about 10 wt. %
to about 80 wt. %; in another embodiment at a level of from about 15 wt.
% to about 80 wt. %; in another embodiment at a level of from about 35
wt. % to about 80 wt. %; in another embodiment at a level of from about
40 wt. % to about 80 wt. %; in another embodiment at a level of from
about 25 wt. % to about 60 wt. %, and in still another embodiment at a
level of from about 40 wt. % to about 50 wt. %, based on the weight of
the rubber modified thermoplastic resin. In other embodiments the rubber
substrate may be present in the rubber modified thermoplastic resin at a
level of from about 5 wt. % to about 50 wt. %; at a level of from about 8
wt. % to about 40 wt. %; or at a level of from about 10 wt. % to about 30
wt. %, based on the weight of the particular rubber modified
thermoplastic resin.

[0014]There is no particular limitation on the particle size distribution
of the rubber substrate (sometimes referred to hereinafter as initial
rubber substrate to distinguish it from the rubber substrate following
grafting). In some embodiments the initial rubber substrate may possess a
broad, essentially monomodal, particle size distribution with particles
ranging in size from about 50 nanometers (nm) to about 1000 nm. In other
embodiments the mean particle size of the initial rubber substrate may be
less than about 100 nm. In still other embodiments the mean particle size
of the initial rubber substrate may be in a range of between about 80 nm
and about 400 nm. In other embodiments the mean particle size of the
initial rubber substrate may be greater than about 400 nm. In still other
embodiments the mean particle size of the initial rubber substrate may be
in a range of between about 400 nm and about 750 nm. In still other
embodiments the initial rubber substrate comprises particles which are a
mixture of particle sizes with at least two mean particle size
distributions. In a particular embodiment the initial rubber substrate
comprises a mixture of particle sizes with each mean particle size
distribution in a range of between about 80 nm and about 750 nm. In
another particular embodiment the initial rubber substrate comprises a
mixture of particle sizes, one with a mean particle size distribution in
a range of between about 80 nm and about 400 nm; and one with a broad and
essentially monomodal mean particle size distribution.

[0015]The rubber substrate may be made according to known methods, such
as, but not limited to, a bulk, solution, or emulsion process. In one
non-limiting embodiment the rubber substrate is made by aqueous emulsion
polymerization in the presence of a free radical initiator, e.g., an
azonitrile initiator, an organic peroxide initiator, a persulfate
initiator or a redox initiator system, and, optionally, in the presence
of a chain transfer agent, e.g., an alkyl mercaptan, to form particles of
rubber substrate.

[0016]The rigid thermoplastic resin phase of the rubber modified
thermoplastic resin comprises one or more thermoplastic polymers. In one
embodiment of the present invention monomers are polymerized in the
presence of the rubber substrate to thereby form a rigid thermoplastic
phase, at least a portion of which is chemically grafted to the rubber
substrate. The portion of the rigid thermoplastic phase chemically
grafted to rubber substrate is sometimes referred to hereinafter as
grafted copolymer. The rigid thermoplastic phase comprises a
thermoplastic polymer or copolymer that exhibits a glass transition
temperature (Tg) in one embodiment of greater than about 25° C.,
in another embodiment of greater than or equal to 90° C., and in
still another embodiment of greater than or equal to 100° C.

[0017]In a particular embodiment the rigid thermoplastic phase comprises a
polymer having structural units derived from one or more monomers
selected from the group consisting of
(C1-C12)alkyl-(meth)acrylate monomers, aryl-(meth)acrylate
monomers, alkenyl aromatic monomers and monoethylenically unsaturated
nitrile monomers. Suitable (C1-C12)alkyl-(meth)acrylate and
aryl-(meth)acrylate monomers, alkenyl aromatic monomers and
monoethylenically unsaturated nitrite monomers include those set forth
hereinabove in the description of the rubber substrate. In addition, the
rigid thermoplastic resin phase may, provided that the Tg limitation for
the phase is satisfied, optionally include up to about 10 wt. % of third
repeating units derived from one or more other copolymerizable monomers.

[0018]The rigid thermoplastic phase typically comprises one or more
alkenyl aromatic polymers. Suitable alkenyl aromatic polymers comprise at
least about 20 wt. % structural units derived from one or more alkenyl
aromatic monomers. In one embodiment the rigid thermoplastic phase
comprises an alkenyl aromatic polymer having structural units derived
from one or more alkenyl aromatic monomers and from one or more
monoethylenically unsaturated nitrile monomers. Examples of such alkenyl
aromatic polymers include, but are not limited to, styrene/acrylonitrile
copolymers, alpha-methylstyrene/acrylonitrile copolymers, or
alpha-methylstyrene/styrene/acrylonitrile copolymers. In another
particular embodiment the rigid thermoplastic phase comprises an alkenyl
aromatic polymer having structural units derived from one or more alkenyl
aromatic monomers; from one or more monoethylenically unsaturated nitrite
monomers; and from one or more monomers selected from the group
consisting of (C1-C12)alkyl- and aryl-(meth)acrylate monomers.
Examples of such alkenyl aromatic polymers include, but are not limited
to, styrene/acrylonitrile/methyl methacrylate copolymers,
alpha-methylstyrene/acrylonitrile/methyl methacrylate copolymers and
alpha-methylstyrene/styrene/acrylonitrile/methyl methacrylate copolymers.
Further examples of suitable alkenyl aromatic polymers comprise
styrene/methyl methacrylate copolymers, styrene/maleic anhydride
copolymers; styrene/acrylonitrile/maleic anhydride copolymers, and
styrene/acrylonitrile/acrylic acid copolymers. These copolymers may be
used for the rigid thermoplastic phase either individually or as
mixtures.

[0019]When structural units comprising the rigid thermoplastic phase are
derived from one or more monoethylenically unsaturated nitrite monomers,
then the amount of nitrite monomer added to form the copolymer comprising
the grafted copolymer and the ungrafted rigid thermoplastic phase may be
in one embodiment in a range of between about 5 wt. % and about 40 wt. %,
in another embodiment in a range of between about 5 wt. % and about 30
wt. %, in another embodiment in a range of between about 10 wt. % and
about 30 wt. %, and in yet another embodiment in a range of between about
15 wt. % and about 30 wt. %, based on the total weight of monomers added
to form the copolymer comprising the grafted copolymer and the ungrafted
rigid thermoplastic phase.

[0020]When structural units comprising the rigid thermoplastic phase are
derived from one or more (C1-C12)alkyl- and aryl-(meth)acrylate
monomers, then the amount of the said monomer added to form the copolymer
comprising the grafted copolymer and the ungrafted rigid thermoplastic
phase may be in one embodiment in a range of between about 5 wt. % and
about 50 wt. %, in another embodiment in a range of between about 5 wt. %
and about 45 wt. %, in another embodiment in a range of between about 10
wt. % and about 35 wt. %, and in yet another embodiment in a range of
between about 15 wt. % and about 35 wt. %, based on the total weight of
monomers added to form the copolymer comprising the grafted copolymer and
the ungrafted rigid thermoplastic phase.

[0021]The amount of grafting that takes place between the rubber substrate
and monomers comprising the rigid thermoplastic phase varies with the
relative amount and composition of the rubber phase. In one embodiment,
greater than about 10 wt. % of the rigid thermoplastic phase is
chemically grafted to the rubber substrate, based on the total amount of
rigid thermoplastic phase in the composition. In another embodiment,
greater than about 15 wt. % of the rigid thermoplastic phase is
chemically grafted to the rubber substrate, based on the total amount of
rigid thermoplastic phase in the composition. In still another
embodiment, greater than about 20 wt. % of the rigid thermoplastic phase
is chemically grafted to the rubber substrate, based on the total amount
of rigid thermoplastic phase in the composition. In particular
embodiments the amount of rigid thermoplastic phase chemically grafted to
the rubber substrate may be in a range of between about 5 wt. % and about
90 wt. %; between about 10 wt. % and about 90 wt. %; between about 15 wt.
% and about 85 wt. %; between about 15 wt. % and about 50 wt. %; or
between about 20 wt. % and about 50 wt. %, based on the total amount of
rigid thermoplastic phase in the composition. In yet other embodiments,
about 40 wt. % to 90 wt. % of the rigid thermoplastic phase is free, that
is, non-grafted.

[0022]The rigid thermoplastic phase may be present in the rubber modified
thermoplastic resin in one embodiment at a level of from about 85 wt. %
to about 6 wt. %; in another embodiment at a level of from about 65 wt. %
to about 6 wt. %; in another embodiment at a level of from about 60 wt. %
to about 20 wt. %; in another embodiment at a level of from about 75 wt.
% to about 40 wt. %, and in still another embodiment at a level of from
about 60 wt. % to about 50 wt. %, based on the weight of the rubber
modified thermoplastic resin. In other embodiments the rigid
thermoplastic phase may be present in a range of between about 90 wt. %
and about 30 wt. %, based on the weight of the rubber modified
thermoplastic resin.

[0023]In one embodiment two or more different rubber substrates, each
possessing a different mean particle size, may be separately employed in
a polymerization reaction to prepare rigid thermoplastic phase, and then
the products blended together to make the rubber modified thermoplastic
resin. In illustrative embodiments wherein such products each possessing
a different mean particle size of initial rubber substrate are blended
together, then the ratios of said substrates may be in a range of about
90:10 to about 10:90, or in a range of about 80:20 to about 20:80, or in
a range of about 75:25 to about 25:75, or in a range of about 70:30 to
about 30:70. In some embodiments an initial rubber substrate with smaller
particle size is the major component in such a blend containing more than
one particle size of initial rubber substrate. In other embodiments
wherein such products each possessing a different mean particle size of
initial rubber substrate are blended together, an initial rubber
substrate with smaller particle size is present in a range of about 85%
to about 65% based on the total amount of rubber substrate employed.

[0024]The rigid thermoplastic phase may be made according to known
processes, for example, mass polymerization, emulsion polymerization,
suspension polymerization or combinations thereof, wherein at least a
portion of the rigid thermoplastic phase is chemically bonded, i.e.,
"grafted" to the rubber phase via reaction with unsaturated sites present
in the rubber phase. The grafting reaction may be performed in a batch,
continuous or semi-continuous process. Representative procedures include,
but are not limited to, those taught in U.S. Pat. No. 3,944,631. The
unsaturated sites in the rubber phase are provided, for example, by
residual unsaturated sites in those structural units of the rubber that
were derived from a graftlinking monomer. In some embodiments of the
present invention monomer grafting to rubber substrate with concomitant
formation of rigid thermoplastic phase may optionally be performed in
stages wherein at least one first monomer is grafted to rubber substrate
followed by at least one second monomer different from said first
monomer. Representative procedures for staged monomer grafting to rubber
substrate include, but are not limited to, those taught in commonly
assigned U.S. Pat. No. 7,049,368.

[0025]In a particular embodiment the rubber modified thermoplastic resin
is an ASA graft copolymer such as that manufactured and sold by General
Electric Company under the trademark GELOY®, and particularly an
acrylate-modified ASA graft copolymer. ASA graft copolymers include, for
example, those disclosed in U.S. Pat. No. 3,711,575. ASA graft copolymers
also comprise those described in commonly assigned U.S. Pat. Nos.
4,731,414 and 4,831,079. In some embodiments of the invention where an
acrylate-modified ASA is used, the ASA component further comprises an
additional acrylate-graft formed from monomers selected from the group
consisting of C1 to C12 alkyl- and aryl-(meth)acrylate as part
of either the rigid phase, the rubber phase, or both. Such copolymers are
referred to as acrylate-modified acrylonitrile-styrene-acrylate graft
copolymers, or acrylate-modified ASA. A particular monomer is methyl
methacrylate to result in a PMMA-modified ASA (sometimes referred to
hereinafter as "MMA-ASA"). The rubber modified thermoplastic resin is
present in compositions of the invention in an amount in one embodiment
in a range of between about 5 wt. % and about 45 wt. %, in another
embodiment in a range of between about 10 wt. % and about 45 wt. %, in
another embodiment in a range of between about 15 wt. % and about 35 wt.
%, and in another embodiment in a range of between about 20 wt. % and
about 35 wt. %, based on the weight of resinous components in the
composition. In some other particular embodiments the rubber modified
thermoplastic resin is present in compositions of the invention in an
amount in a range of between about 30 wt. % and about 45 wt. % based on
the weight of resinous components in the composition.

[0026]Compositions in embodiments of the present invention comprise a
separately synthesized rigid thermoplastic resinous component (referred
to sometimes hereinafter as the "second thermoplastic resin") comprising
structural units derived from a mixture of at least one alkenyl aromatic
monomer and at least one monoethylenically unsaturated nitrile monomer.
Suitable alkenyl aromatic monomers include, but are not limited to, vinyl
aromatic monomers, such as, for example, styrene and substituted styrenes
having one or more alkyl, alkoxy, hydroxy or halo substituent groups
attached to the aromatic ring, including, but not limited to,
alpha-methyl styrene, p-methyl styrene, 3,5-diethylstyrene,
4-n-propylstyrene, 4-isopropylstyrene, vinyl toluene, alpha-methyl vinyl
toluene, vinyl xylene, trimethyl styrene, butyl styrene, t-butyl styrene,
chlorostyrene, alpha-chlorostyrene, dichlorostyrene, tetrachlorostyrene,
bromostyrene, alpha-bromostyrene, dibromostyrene, p-hydroxystyrene,
p-acetoxystyrene, methoxystyrene and vinyl-substituted condensed aromatic
ring structures, such as, for example, vinyl naphthalene, vinyl
anthracene. Substituted styrenes with mixtures of substituents on the
aromatic ring are also suitable. As used herein, the term
"monoethylenically unsaturated nitrite monomer" means an acyclic compound
that includes a single nitrite group and a single site of ethylenic
unsaturation per molecule and includes, but is not limited to,
acrylonitrile, methacrylonitrile, ethacrylonitrile,
alpha-chloroacrylonitrile, alpha-bromoacrylonitrile, and the like. In
some embodiments the separately synthesized rigid thermoplastic polymer
comprises structural units essentially identical to those of the rigid
thermoplastic phase comprising the rubber modified thermoplastic resin.
In some particular embodiments the separately synthesized rigid
thermoplastic polymer comprises structural units derived from styrene and
acrylonitrile; alpha-methylstyrene and acrylonitrile;
alpha-methylstyrene, styrene, and acrylonitrile; styrene, acrylonitrile,
and methyl methacrylate; alpha-methyl styrene, acrylonitrile, and methyl
methacrylate; or alpha-methylstyrene, styrene, acrylonitrile, and methyl
methacrylate, or the like or mixtures thereof. The second thermoplastic
resin is present in compositions of the invention in an amount in one
embodiment in a range of between about 5 wt. % and about 60 wt. %, in
another embodiment in a range of between about 5 wt. % and about 55 wt.
%, in another embodiment in a range of between about 10 wt. % and about
55 wt. %, in another embodiment in a range of between about 15 wt. % and
about 35 wt. %, and in another embodiment in a range of between about 20
wt. % and about 35 wt. %, based on the weight of resinous components in
the composition. In some particular embodiments the second thermoplastic
resin is present in compositions of the invention in a range of between
about 35 wt. % and about 55 wt. %, based on the weight of resinous
components in the composition.

[0028]wherein each R1 is independently halogen or C1-12 alkyl, p
is 0-3, each R2 is independently a divalent organic radical, m is at
least 1 and n is at least about 4. In some particular embodiments n is at
least about 10, more particularly at least about 20 and still more
particularly in a range of about 30-150. In other particular embodiments
m is at least about 3, more particularly at least about 10 and still more
particularly in a range of about 20-200. In still other particular
embodiments m is between about 20 and 50. In some other particular
embodiments the ratio m:n is in a range of 1:99 to 99:5. Within the
context of the invention "alternating carbonate and arylate blocks" means
that the polyestercarbonates comprise at least one carbonate block and at
least one arylate block.

[0029]The arylate blocks comprise structural units derived from
1,3-dihydroxybenzene moieties (sometimes referred to herein after as
"resorcinol") which may be unsubstituted or substituted. Alkyl
substituents, if present, may be straight-chain or branched alkyl groups,
and are most often located in the ortho position to both oxygen atoms
although other ring locations are contemplated. Suitable C1-12 alkyl
groups include methyl, ethyl, n-propyl, isopropyl, butyl, iso-butyl,
t-butyl, nonyl, decyl, and aryl-substituted alkyl, including benzyl. In
one particular embodiment the alkyl group substituent, when present, is
methyl. Suitable halogen substituents include bromo, chloro, and fluoro.
1,3-Dihydroxybenzene moieties comprising a mixture of alkyl and halogen
substituents are also suitable. The value for p may be 0-3, particularly
0-2, and more particularly 0-1. In one embodiment the
1,3-dihydroxybenzene moiety is 2-methylresorcinol. In other embodiments
the 1,3-dihydroxybenzene moiety is unsubstituted resorcinol in which p is
zero. Polymers containing structural units derived from mixtures of
1,3-dihydroxybenzene moieties, such as a mixture of unsubstituted
resorcinol with 2-methylresorcinol are also contemplated.

[0030]In the arylate structural units said 1,3-dihydroxybenzene moieties
are bound to aromatic dicarboxylic acid moieties which may be monocyclic
moieties, such as, but not limited to, isophthalate or terephthalate or
their alkyl or halogen substituted derivatives; or polycyclic moieties,
such as, but not limited to, biphenyl dicarboxylate, diphenylether
dicarboxylate, diphenylsulfone dicarboxylate, diphenylketone
dicarboxylate, diphenylsulfide dicarboxylate, or
naphthalenedicarboxylate, and particularly naphthalene-2,6-dicarboxylate;
or mixtures of monocyclic and/or polycyclic aromatic dicarboxylates. In
particular embodiments the aromatic dicarboxylic acid moieties are
isophthalate and/or terephthalate. Either or both of said moieties may be
present. In many embodiments both are present in a molar ratio of
isophthalate to terephthalate in the range of about 0.20-4.0:1. When the
isophthalate to terephthalate ratio is greater than about 4.0:1, then
unacceptable levels of cyclic oligomer may form. When the isophthalate to
terephthalate ratio is less than about 0.25:1, then unacceptable levels
of insoluble polymer may form. In particular embodiments the molar ratio
of isophthalate to terephthalate is about 0.4-2.5:1, and more
particularly about 0.67-1.5:1.

[0031]In the carbonate blocks, each R2 is independently an organic
radical derived from a dihydroxy compound. In particular embodiments at
least about 60 percent of the total number of R2 groups in the
polymer are aromatic organic radicals and the balance thereof comprise
aliphatic, alicyclic, or aromatic radicals, or mixtures thereof. Suitable
R2 radicals comprise m-phenylene, p-phenylene, 4,4'-biphenylene,
4,4'-bi(3,5-dimethyl)-phenylene, 2,2-bis(4-phenylene)propane and similar
radicals such as those which correspond to the dihydroxy-substituted
aromatic hydrocarbons disclosed by name or formula (generic or specific)
in U.S. Pat. No. 4,217,438. Included among suitable dihydroxy-substituted
aromatic hydrocarbons are the
2,2,2',2'-tetrahydro-1,1'-spirobi[1H-indene]diols having formula (II):

##STR00002##

[0032]wherein each R3 is independently selected from monovalent
hydrocarbon radicals and halogen radicals; each R4, R5,
R6, and R7 is independently C1-6 alkyl; each R8 and
R9 is independently H or C1-6 alkyl; and each n is
independently selected from positive integers having a value of from 0 to
3 inclusive. A preferred
2,2,2',2'-tetrahydro-1,1'-spirobi[1H-indene]-diol is
2,2,2',2'-tetrahydro-3,3,3,3'-tetramethyl-1,1'-spirobi[1H-indene]-6,6'-di-
ol.

[0033]In other particular embodiments, each R2 of formula (I) is an
aromatic organic radical and still more particularly a radical of the
formula (II):

-A1-Y A2-, (III)

[0034]wherein each A1 and A2 is a monocyclic divalent aryl
radical and Y is a bridging radical in which one or two carbon atoms
separate A1 and A2. The free valence bonds in formula (III) are
usually in the meta or para positions of A1 and A2 in relation
to Y. Compounds in which R2 has formula (III) are bisphenols, and
for the sake of brevity the term "bisphenol" is sometimes used herein to
designate the dihydroxy-substituted aromatic hydrocarbons; it should be
understood, however, that non-bisphenol compounds of this type may also
be employed as appropriate.

[0035]In formula (III), A1 and A2 typically represent
unsubstituted phenylene or substituted derivatives thereof illustrative
substituents (one or more) comprising alkyl, alkenyl, and halogen
(particularly bromine). In a particular embodiment phenylene radicals are
unsubstituted. In one embodiment both A1 and A2 are
p-phenylene, although both may be o- or m-phenylene or one o- or
m-phenylene and the other p-phenylene.

[0036]The bridging radical, Y, is one in which one or two atoms separate
A1 from A2. In one embodiment one atom separates A1 from
A2. Illustrative radicals of this type comprise --C═O, --O--,
--S--, --SO-- or --SO2--, methylene, cyclohexylmethylene,
2-[2.2.1]-bicycloheptyl methylene, ethylene, isopropylidene,
neopentylidene, cyclohexylidene, cyclopentadecylidene, cyclododecylidene,
and adamantylidene. In some embodiments the bridging radical, Y, is a
gem-alkylene radical. Also included, however, are unsaturated radicals.
For reasons of availability and particular suitability for the purposes
of this invention, a particular bisphenol is
2,2-bis(4-hydroxy-phenyl)propane (hereinafter referred to as bisphenol A
or BPA), in which Y is isopropylidene and A1 and A2 are each
p-phenylene.

[0037]In some embodiments R2 in the carbonate blocks may consist of
or at least partially comprise a radical derived from a
1,3-dihydroxybenzene moiety. Therefore, in one embodiment of the present
invention the polyestercarbonates comprise carbonate blocks with R2
radicals derived from a dihydroxy compound identical to at least one
1,3-dihydroxybenzene moiety in the polyarylate blocks. In another
embodiment the polyestercarbonates comprise carbonate blocks with R2
radicals derived from a dihydroxy compound different from any
1,3-dihydroxybenzene moiety in the polyarylate blocks. In yet another
embodiment the polyestercarbonates comprise carbonate blocks containing a
mixture of R2 radicals derived from dihydroxy compounds at least one
of which is the same as and at least one of which is different from any
1,3-dihydroxybenzene moiety in the polyarylate blocks. When a mixture of
R2 radicals derived from dihydroxy compounds is present, then the
molar ratio of dihydroxy compounds identical to those present in the
polyarylate blocks to those dihydroxy compounds different from those
present in the polyarylate blocks is typically about 1:999 to 999:1. In
some particular embodiments the polyestercarbonates comprise carbonate
blocks containing a mixture of R2 radicals derived from at least two
of unsubstituted resorcinol, a substituted resorcinol, and bisphenol A.

[0038]Diblock, triblock, and multiblock polyestercarbonates are
encompassed in the present invention. The chemical linkages between
blocks comprising arylate chain members and blocks comprising organic
carbonate chain members typically comprise a carbonate linkage between a
diphenol residue of an arylate moiety and a--(C═O)--O-- moiety of an
organic carbonate moiety, although other types of linkages such as ester
and/or anhydride are also possible. A representative carbonate linkage
between said blocks is shown in formula (IV), wherein R1 and p are
as previously defined:

##STR00003##

[0039]In some embodiments the polyestercarbonates are substantially free
of anhydride linkages. "Substantially free of anhydride linkages" means
that the polyestercarbonate shows a decrease in molecular weight of less
than 10% upon heating said polyestercarbonate at a temperature of about
280° C. to 290° C. for five minutes. In more particular
embodiments, the polyestercarbonate shows a decrease of molecular weight
of less than 5% upon heating said polyestercarbonate at a temperature of
about 280° C. to 290° C. for five minutes.

[0040]In one embodiment the polyestercarbonate is substantially comprised
of a diblock copolymer with a carbonate linkage between an arylate block
and an organic carbonate block. In another embodiment the
polyestercarbonate is substantially comprised of a triblock
carbonate-ester-carbonate copolymer with carbonate linkages between the
arylate block and organic carbonate end-blocks. Polyestercarbonates with
at least one carbonate linkage between an arylate block and an organic
carbonate block are typically prepared from 1,3-dihydroxybenzene
arylate-containing oligomers containing at least one and preferably two
hydroxy-terminal sites (hereinafter sometimes referred to as
hydroxy-terminated polyester intermediate).

[0042]wherein R1, p, and n are as previously defined, and the arylate
structural units are as described for formula (I). Polyestercarbonates
comprising formula (V) may arise from reaction of hydroxy-terminated
polyester intermediate with a carbonate precursor in the substantial
absence of any dihydroxy compound different from the hydroxy-terminated
polyester intermediate.

[0043]In the polyestercarbonates in embodiments of the present invention
the distribution of the blocks may be such as to provide a copolymer
having any desired weight proportion of arylate blocks in relation to
carbonate blocks. In some particular embodiments, the polyestercarbonates
comprise about 10-99% by weight arylate blocks. In other particular
embodiments, the polyestercarbonates comprise about 10-25% by weight
arylate blocks. In other particular embodiments, the polyestercarbonates
comprise at least 40% by weight arylate blocks. In yet other particular
embodiments, the copolymers comprise about 45-60% by weight arylate
blocks. In still other particular embodiments, the polyestercarbonates
comprise at least 75% by weight arylate blocks. In still other particular
embodiments, the polyestercarbonates comprise about 75-90% by weight
arylate blocks. Mixtures of polyestercarbonates comprising different
molecular weights and different ratios of arylate blocks to carbonate
blocks may also be employed. Suitable polyestercarbonates may be prepared
by methods known in the art including, but not limited to, those methods
taught in U.S. Pat. Nos. 6,306,507, 6,559,270 and 6,583,256.
Polyestercarbonates suitable for use in the invention may have different
end-groups. In some embodiments end-groups arise from the use of a
chain-stopper in the polyestercarbonate preparation. Illustrative
chain-stoppers comprise at least one of mono-phenolic compounds,
mono-carboxylic acid chlorides, and/or mono-chloroformates.

[0044]The polyestercarbonate is present in compositions of the invention
in an amount in a range of between about 2 wt. % and about 82 wt. %. In
some particular embodiments, the polyestercarbonate is present in
compositions of the invention in an amount in one exemplary embodiment in
a range of between about 2 wt. % and about 25 wt. %, in another exemplary
embodiment in a range of between about 2 wt. % and about 21 wt. %, and in
another exemplary embodiment in a range of between about 2 wt. % and
about 9 wt. %, based on the weight of resinous components in the
composition. In other particular embodiments, the polyestercarbonate is
present in compositions of the invention in an amount in one exemplary
embodiment in a range of between about 20 wt. % and about 80 wt. %, and
in another exemplary embodiment in a range of between about 30 wt. % and
about 75 wt. %, based on the weight of resinous components in the
composition. In other particular embodiments the polyestercarbonate is
present in compositions of the invention in an amount in a range of
between about 30 wt. % and about 60 wt. %, based on the weight of
resinous components in the composition

[0045]Compositions of the present invention may also optionally comprise
additives known in the art including, but not limited to, stabilizers,
such as flame retardants, color stabilizers, heat stabilizers, light
stabilizers, antioxidants, UV screeners, and UV absorbers; lubricants,
flow promoters and other processing aids; plasticizers, antistatic
agents, mold release agents, impact modifiers, fillers, and colorants
such as dyes and pigments which may be organic, inorganic or
organometallic; and like additives. Illustrative additives include, but
are not limited to, silicone oil, pentaerythritol tetrastearate, hindered
amine light stabilizers, phosphite stabilizers, silica, silicates,
zeolites, titanium dioxide, stone powder, glass fibers or spheres, carbon
fibers, carbon black, graphite, calcium carbonate, talc, lithopone, zinc
oxide, zirconium silicate, iron oxides, diatomaceous earth, calcium
carbonate, magnesium oxide, chromic oxide, zirconium oxide, aluminum
oxide, crushed quartz, clay, calcined clay, talc, kaolin, asbestos,
cellulose, wood flour, cork, cotton and synthetic textile fibers,
especially reinforcing fillers such as glass fibers, carbon fibers, metal
fibers, and metal flakes, including, but not limited to aluminum flakes.
Often more than one additive is included in compositions of the
invention, and in some embodiments more than one additive of one type is
included. In a particular embodiment a composition in an embodiment of
the invention further comprises an additive selected from the group
consisting of colorants, dyes, pigments, lubricants, stabilizers, heat
stabilizers, light stabilizers, antioxidants, UV screeners, UV absorbers,
fillers and mixtures thereof. In yet another particular embodiment a
composition in an embodiment of the invention further comprises an
additive selected from the group consisting of lubricants, stabilizers,
antioxidants and mixtures thereof. In other particular embodiments
compositions of the invention are free of a poly(alkylene dicarboxylate),
such as, but not limited to, poly(butylene terephthalate).

[0046]Compositions of the invention and articles made therefrom may be
prepared by known thermoplastic processing techniques. Known
thermoplastic processing techniques which may be used include, but are
not limited to, extrusion, calendering, kneading, profile extrusion,
sheet extrusion, coextrusion, molding, extrusion blow molding,
thermoforming, injection molding, co-injection molding and rotomolding.
The invention further contemplates additional fabrication operations on
said articles, such as, but not limited to, in-mold decoration, baking in
a paint oven, surface etching, lamination, and/or thermoforming.
Compositions of the invention may also comprise regrind or reworked
resinous components.

[0047]In some embodiments of the present invention compositions may be
suitable for use in applications that require high notched Izod impact
strength (NII) values in molded articles. Articles molded from
compositions in some embodiments of the invention exhibit NII values in
one particular embodiment of greater than or equal to about 5 kilojoules
per square meter (kJ/m2), in another particular embodiment of
greater than or equal to about 15 kJ/m2, in another particular
embodiment of greater than or equal to about 20 kJ/m2, in still
another particular embodiment of greater than or equal to about 25
kJ/m2 and in still another particular embodiment of greater than or
equal to about 30 kJ/m2, as determined according to ISO 180 at room
temperature. Compositions in other embodiments of the invention show no
decrease of impact strength over a range of polyestercarbonate levels, in
contrast to similar compositions containing comparable amounts of
polycarbonate which show decrease in impact strength. In the present
context decrease of impact strength over a range of polyestercarbonate
levels means that the compositions show less than 10% decrease in notched
Izod impact strength (NII) values determined according to ISO 180 at room
temperature. In a particular embodiment compositions of the invention
show less than 10% decrease in notched Izod impact strength over a range
of 5-20 wt. % polyestercarbonate content, based on the weight of the
entire composition. Polyestercarbonate-comprising compositions in still
other embodiments of the invention may be suitable for use in
applications that require higher impact strength but also comparable heat
properties or higher heat properties than can be obtained in similar
compositions comprising comparable amounts of polycarbonate.

[0049]Without further elaboration, it is believed that one skilled in the
art can, using the description herein, utilize the present invention to
its fullest extent. The following examples are included to provide
additional guidance to those skilled in the art in practicing the claimed
invention. The examples provided are merely representative of the work
that contributes to the teaching of the present application. Accordingly,
these examples are not intended to limit the invention, as defined in the
appended claims, in any manner.

[0050]In the following examples ASA was a copolymer comprising structural
units derived from about 28-34 wt. % styrene, about 10-18 wt. %
acrylonitrile, about 5-15 wt. % methyl methacrylate, and about 40-48 wt.
% butyl acrylate. Polyestercarbonates (PEC) all comprised structural
units derived from isophthalic and terephthalic acids present in a ratio
in a range of about 40-60%, and resorcinol. PEC-1 was a block
polyestercarbonate comprising ester structural units present in an amount
in a range of about 10-25% and carbonate structural units present in an
amount in a range of about 90-75% with a molecular weight in a range of
about 22,000-32,000; PEC-2 was a block polyestercarbonate comprising
ester structural units present in an amount in a range of about 75-90%
and carbonate structural units present in an amount in a range of about
20-10% with a molecular weight in a range of about 18,000-24,000; and
PEC-3 was a block polyestercarbonate comprising ester structural units
present in an amount in a range of about 45-60% and carbonate structural
units present in an amount in a range of about 55-40% with a molecular
weight in a range of about 22,000-32,000; all determined according to
polycarbonate standards. In comparative examples the polycarbonate (PC)
employed was a bisphenol-A polycarbonate. MMASAN was copolymer comprising
structural units derived from about 30-40% methyl methacrylate, about
35-45% styrene and about 20-30% acrylonitrile. AMSAN was a copolymer
comprising structural units derived from about 60-75% alpha-methyl
styrene and about 25-40% acrylonitrile. SAN was a copolymer comprising
structural units derived from about 70-80% styrene and about 20-30%
acrylonitrile.

[0051]Vicat B data at 120° C. were determined according to ISO 306.
Weathering on test parts was performed according to the SAEJ1960 protocol
on molded discs through 2500 kJ/m2 exposure (measured at 340 nm).
Melt volume rate (MVR) values was determined at 260° C. using a 5
kilogram weight according to ISO 1133. Notched Izod impact strength (NII)
values were determined according to ISO 180 at room temperature. In the
following examples the amounts of components are expressed in wt. %
unless noted.

EXAMPLES 1-4 AND COMPARATIVE EXAMPLES 1-7

[0052]Compositions were compounded from the components shown in Table 1.
Each composition contained in addition 2 parts per hundred parts resinous
components (phr; wherein resinous components comprise polyestercarbonate,
ASA, MMASAN, and AMSAN) of carbon black and 1.8 phr of a mixture of
lubricants, stabilizers and antioxidants. Comparative examples (C.Ex.)
were prepared with bisphenol A polycarbonate. The compounded material was
molded into test parts and the parts were tested for notched Izod impact
strength and Vicat B properties. The test results are shown in Table 1.

[0053]Compositions in embodiments of the invention comprising
polyestercarbonate (Examples 1-4) surprisingly show good heat properties
and also higher impact strength than comparative examples comprising
polycarbonate. In particular, Example 2 comprising polyestercarbonate
shows no reduction and even a slight increase in notched Izod impact
strength in comparison to comparative example 3 comprising polycarbonate.
The data in Table 1 show that the notched Izod impact strength of blends
decreases upon the addition of increasing levels of polycarbonate but
increases with the addition of increasing levels of polyestercarbonate.
This is particularly unexpected since the notched Izod impact strength of
polycarbonate is a higher measured value than that of polyestercarbonate.

[0054]The Vicat B heat values shown in Table 1 show that the addition of
polycarbonate or polyestercarbonate to the ASA formulations has a
comparable influence on the heat properties of the blends. This is also
surprising since the glass transition temperature of polyestercarbonate
is significantly lower than the glass transition temperature of
polycarbonate (136° C. vs. 145° C., respectively). A person
skilled in the art would therefore expect that the improvement in heat
for polyestercarbonate would be less than with polycarbonate. In
contrast, it is observed that the improvement in heat properties is about
the same or slightly better than with polycarbonate, which is unexpected.
The combination of increased impact strength and good heat properties
makes these compositions comprising polyestercarbonate suitable for many
commercial uses.

EXAMPLES 5-12 AND COMPARATIVE EXAMPLES 8-9

[0055]Compositions were compounded from the components shown in Table 2.
Each composition contained in addition 2 phr of carbon black and 1.8 phr
of a mixture of lubricants, stabilizers and antioxidants. The compounded
material was molded into test parts and the parts were tested for notched
Izod impact strength properties. The test results are shown in Table 2.

[0056]The compositions of examples 5-12 show that there is an unexpected
increase in impact strength in the compositions containing
polyestercarbonate in comparison to the corresponding compositions of
comparative examples 2-5 (Table 1) containing polycarbonate. In
particular, the compositions of comparative examples 2-5 show a decrease
in impact strength with increasing levels of polycarbonate while the
compositions of examples 5-12 show an increase in impact strength with
increasing levels of polyestercarbonate. Again, this is particularly
unexpected since the notched Izod impact strength of polycarbonate (15
kJ/m2) is a higher measured value than that of the
polyestercarbonates PEC-1, PEC-2 and PEC-3.

EXAMPLES 13-22 AND COMPARATIVE EXAMPLE 8

[0057]Compositions were compounded from the components shown in Table 3.
Each composition contained in addition 0.5 phr (wherein resinous
components comprise polyestercarbonate, ASA and SAN) of carbon black, 0.5
phr of a mixture of lubricants, stabilizers and antioxidants 4 phr of an
acrylic polymer comprising structural units derived from methyl
methacrylate and at least one (C1-C12)alkyl acrylate monomer.
The compounded material was molded into test parts and the parts were
tested for notched Izod impact strength properties. The test results are
shown in Table 3.

[0058]Unexpectedly, the results show that there is a sharp increase in NII
value above about 20% PEC level but there is no decrease in
weatherability (as measured by dE value) until much higher levels of PEC
are reached. The balance between notched Izod impact and resistance to
discoloration upon weathering is better in the range between 20 and 80%
polyestercarbonate than could be expected. Flow properties (i.e. MVR
values) decrease with increasing levels of polyestercarbonate, while
Vicat B heat values beneficially increase with increasing levels of
polyestercarbonate.

[0059]While the invention has been illustrated and described in typical
embodiments, it is not intended to be limited to the details shown, since
various modifications and substitutions can be made without departing in
any way from the spirit of the present invention. As such, further
modifications and equivalents of the invention herein disclosed may occur
to persons skilled in the art using no more than routine experimentation,
and all such modifications and equivalents are believed to be within the
spirit and scope of the invention as defined by the following claims. All
patents and published articles cited herein are incorporated herein by
reference.